Part 2
Part 1 Of 2:
Part 2 Of 2:
DIFFERENTIAL CARRIER ASSEMBLY REAR
OVERHAUL
55. INSTALL REAR DIFFERENTIAL CASE BEARING
a. Using SST(s) and a press, install the case bearing (LH) to the differential case.
SST 09636-20010
56. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR
a. Install the differential case to the carrier, and install the 2 plate washers so that there is no play in the bearing.
b. Install the 2 bearing caps with the 4 bolts.
Torque: 79 Nm (800 kgf-cm, 58 ft. lbs.)
c. Using a dial gauge, measure the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 inch)
d. Remove the 2 bearing caps, 2 plate washers and differential carrier.
57. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Using SST(s) and a press, install the front bearing (outer race) to the carrier.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)
58. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Using SST(s) and a press, install the rear bearing (outer race) to the carrier.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)
59. INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING
a. Install the removed plate washer to the drive pinion.
b. Using SST(s) and a press, install the rear bearing to the drive pinion.
SST 09506-30012
60. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
a. Install the drive pinion and front bearing.
HINT: Assemble the spacer and oil seal after adjusting the gear contact pattern.
b. Install the rear differential drive pinion oil slinger to the drive pinion.
c. Using SST(s), install the companion flange.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
d. Coat the threads of the nut with hypoid gear oil LSD.
e. Using SST(s) to hold the flange, torque the nut.
SST 09330-00021
Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.)
NOTICE:
^ Torque the nut a little at a time, being careful not to overtighten it.
^ Apply hypoid gear oil LSD to the nut.
f. Using a torque wrench, measure the preload
Preload (at starting):
New bearing: 1.1 to 1.7 Nm (11 to 17 kgf-cm, 9.6 to 14.8 inch lbs.)
Reused bearing: 0.6 to 0.9 Nm (6 to 9 kgf-cm, 5.2 to 7.8 inch lbs.)
61. INSTALL DIFFERENTIAL CASE ASSEMBLY
a. Place the 2 bearing outer races on their respective bearings. Make sure the right and left races are not interchanged
62. ADJUST DIFFERENTIAL RING GEAR BACKLASH
a. Install the right and left bearing caps with the 4 bolts.
Torque: 79 Nm (800 kgf-cm, 58 ft. lbs.)
HINT:
^ When using a new side bearing select a thrust shim which is thinner than the removed one.
^ If the side bearing is reused, select a thrust shim of the same thickness as the removed one.
b. Make snug the differential case bearing and thrust shim by tapping on the ring gear with a plastic hammer.
c. Set the dial gauge perpendicular to the end of the ring gear face.
d. While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash.
Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 inch)
NOTICE: Measure it at 3 points or more on the ring gear periphery.
If the measured value is out of the specified value, select a proper thrust shim so that the backlash of the differential ring gear is within the value, and install it to the ring gear back side.
Washer thickness
63. ADJUST TOTAL PRELOAD
a. After adjusting the backlash of the differential ring gear, remove the teeth side thrust shim.
b. Using a micrometer, measure the thickness of the removed thrust shim.
c. Select a new thrust shim 0.06 to 0.09 mm (0.0024 to 0.0035 inch) which is thicker than the removed one.
HINT: Select a thrust shim which can be pressed in 2/3rds of the way by finger.
d. Using SST(s) and a plastic hammer, drive in the thrust shim.
SST 09504-22011
e. Align matchmarks on the bearing cap and differential carrier, and install the 2 bearing caps.
NOTICE: Make sure the right and left bearing caps are not interchanged.
f. Tighten both bearing caps with the 4 bolts.
Torque: 79 Nm (800 kgf-cm, 58 ft. lbs.)
g. Set the dial gauge to the end of the differential ring gear face.
h. While holding the rear drive pinion companion flange rear, rotate the differential ring gear and measure the backlash.
Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 inch)
i. If the measured value is out of the specified value, adjust it by increasing or decreasing the thickness of both right and left thrust shims equally.
SST 09504-22011
j. Using a torque wrench, measure the preload. Total preload (at starting):
Drive pinion preload plus 0.3 to 0.5 Nm (3 to 5 kgf-cm, 2.6 to 4.3 inch lbs.)
64. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
a. Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer.
b. Hold the companion flange firmly and rotate the ring gear in both directions.
c. Inspect the tooth contact pattern.
If the teeth are not contacting properly, use the following table to select a proper washer for correction.
Washer thickness
65. REMOVE REAR DRIVE PINION NUT (See step 32)
SST 09330-00021
66. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR (See step 33)
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
67. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
68. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (See step 37)
SST 09556-22010
69. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
a. Install a new bearing spacer.
70. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
a. Install the rear drive pinion front tapered roller bearing to the drive pinion.
71. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
a. Install the rear differential drive pinion oil slinger to the drive pinion.
72. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
a. Using SST(s) and a hammer, install a new oil seal.
SST 09554-22010
Oil seal drive in depth: 2.0 ± 0.3 mm (0.079 ± 0.012 inch)
b. Apply MP grease to the oil seal lip.
73. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR
a. Using SST(s) and a press, install a new dust deflector.
SST 09223-00010
NOTICE: Be careful not to damage the dust deflector.
74. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR
a. Using SST(s), install the companion flange to the drive pinion.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)
b. Coat the threads of a new nut with hypoid gear oil LSD.
c. Using SST(s) to hold the flange, torque the nut.
SST 09330-00021
Torque: 108 Nm (1,100 kgf-cm, 80 ft. lbs.)
75. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
a. Using a torque wrench, measure the preload of the drive pinion.
Preload (at starting):
New bearing: 1.1 to 1.7 Nm (11 to 17 kgf-cm, 9.6 to 14.8 inch lbs.)
Reused bearing: 0.6 to 0.9 Nm (6 to 9 kgf-cm, 5.2 to 7.8 inch lbs.)
^ If the preload is greater than the specification, re place the bearing spacer.
^ If the preload is less than the specification, re torque the nut with 13 Nm (130 kgf-cm, 9 ft. lbs.) of torque at a time until the specified preload is reached.
Torque: 235 Nm (2,400 kgf-cm, 174 ft. lbs.) or less
^ If the torque exceeds the maximum while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure.
NOTICE: Do not loosen the pinion nut to reduce the preload.
HINT: This preload is within the backlash between the drive pinion and ring gear.
76. INSPECT TOTAL PRELOAD
a. Using a torque wrench, measure the preload. Total preload (at starting):
Drive pinion preload plus 0.3 to 0.5 Nm (3 to 5 kgf-cm, 2.6 to 4.3 inch lbs.)
77. INSPECT DIFFERENTIAL RING GEAR BACKLASH (See step 25)
78. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR (See step 28)
79. INSTALL REAR DRIVE PINION NUT
80. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL
a. Using SST(s) and a hammer, install 2 new oil seals.
SST 09550-00032, 09950-70010 (09951-07200)
Oil seal drive in depth: 0 ± 0.5 mm (0 ± 0.019 inch)
b. Apply MP grease to the oil seal lip.
81. INSTALL REAR DIFFERENTIAL CARRIER COVER
a. Install the breather plug to the carrier cover.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)
b. Clean contacting surfaces of any residual FIPG material using gasoline or alcohol.
c. Apply FIPG to the carrier.
FIPG: 08826-00090, THREE BOND 1281 or equivalent
HINT:
^ FIPG should be applied 2 to 3 mm (0.08 to 0.12 inch) in diameter with no break.
^ Allow for an overlap of 10 mm (0.37 inch) or more between the start and end of FIPG application.
^ Install the carrier cover within 3 minutes after applying FIPG.
^ Do not add oil or drive the vehicle immediately after installing the cover, and leave it as is for at least an hour or more.
Also, for 12 hours or more, avoid rapid acceleration/deceleration.
d. Install the carrier cover with the 8 bolts.
Torque: 47 Nm (475 kgf-cm, 34 ft. lbs.)
82. INSTALL REAR DIFFERENTIAL SUPPORT NO.1
a. Install the rear differential support No.1 to the differential carrier assembly rear with the 2 bolts and 2 lock nuts
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
83. INSTALL DIFFERENTIAL CARRIER ASSEMBLY REAR
a. Jack up the differential carrier assembly rear and rear suspension member with a jack.
b. Connect the rear differential support No 1 to the rear suspension member with 2 bolts and 2 lock nuts
Torque: 137 Nm (1,400 kgf-cm, 101 ft. lbs.)
c. Install the differential carrier assembly rear to the rear suspension member sub-assembly with the 3 bolts.
Torque: 95 Nm (970 kgf-cm, 70 ft. lbs.)
84. INSTALL REAR SUSPENSION MEMBER SUB-ASSEMBLY
85. INSTALL REAR DRIVE SHAFT ASSEMBLY LH
86. INSTALL REAR DRIVE SHAFT ASSEMBLY RH
HINT: Installation procedure of the RH side is the same as that of the LH side.
87. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.2 LH
88. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.2 RH
HINT: Installation procedure of the RH side is the same as that of the LH side.
89. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.1 LH
90. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.1 RH
HINT: Installation procedure of the RH side is the same as that of the LH side.
91. TEMPORARILY TIGHTEN STRUT ROD ASSEMBLY REAR
92. INSTALL REAR AXLE SHAFT LH NUT
SST 09930-00010
93. INSTALL REAR AXLE SHAFT RH NUT
SST 09930-00010
HINT: Installation procedure of the RH side is the same as that of the LH side.
94. INSTALL SPEED SENSOR REAR LH
95. INSTALL SPEED SENSOR REAR RH
HINT: Installation procedure of the RH side is the same as that of the LH side.
96. STABILIZE SUSPENSION
97. FULLY TIGHTEN STRUT ROD ASSEMBLY REAR
98. FULLY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.2 LH
99. FULLY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.2 RH
HINT: Installation procedure of the RH side is the same as that of the LH side.
100. FULLY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.1 LH
101. FULLY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.1 RH
HINT: Installation procedure of the RH side is the same as that of the LH side.
102. INSTALL EXHAUST PIPE ASSEMBLY
103. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSEMBLY
104. FULLY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSEMBLY
SST 09370-50010
105. INSTALL ENGINE UNDER COVER NO.2 (W/ ENGINE UNDER COVER NO.2)
106. INSTALL ENGINE UNDER COVER ASSEMBLY
107. INSTALL REAR DIFFERENTIAL DRAIN PLUG
a. Using a hexagon wrench (10 mm), install the drain plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
108. ADD DIFFERENTIAL OIL
a. Fill the rear differential carrier assembly with hypoid gear oil.
Oil grade: Hypoid gear oil API GL-5
Recommended oil viscosity:
Above -18°C (0°F) SAE 90
Below -18°C (0°F) SAE 80W or 80W-90
Capacity: 0.9 ± 0.05 liters (0.95 ± 0.05 US qts, 0.79 ± 0.04 Imp. qts)
109. INSPECT DIFFERENTIAL OIL
110. INSTALL REAR DIFFERENTIAL FILLER PLUG
a. Using a hexagon wrench (10 mm), install the filler plug with a new gasket
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
111. INSTALL REAR WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
112. INSPECT AND ADJUST REAR WHEEL ALIGNMENT
113. CHECK FOR EXHAUST GAS LEAKS
114. ADJUST VEHICLE HEIGHT (W/ AIR SUSPENSION)
115. ADJUST HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP)
116. CHECK ABS SPEED SENSOR SIGNAL